阅读说明：本技术 具有端子位置保证构件的电连接器 (Electric connector with terminal position assurance member ) 是由 A.J.德沙扎尔 G.巴特 T.K.萨拉卡 于 2018-11-12 设计创作，主要内容包括：一种电连接器(100),包括外壳(102)和端子位置保证(TPA)构件(104)。外壳限定多个腔室(108),其在外壳(102)的配合端和电缆端(114,112)之间延伸,且平行于腔室轴线(120)定向。外壳(102)将电端子(106)保持在腔室(108)内,以电连接到配合连接器的配合触头。TPA构件(104)安装到外壳(102)的电缆端(112)且可相对于外壳(102)在解锁位置和锁定位置之间移动。TPA构件(104)沿着垂直于腔室轴线(120)的致动轴线(134)从解锁位置移动到锁定位置。TPA构件(104)包括壁架(224),当TPA构件(104)处于锁定位置时,壁架凸出到外壳(102)的腔室(108)中且凸出到端子(106)的对应的后撤路径(232)中,以阻止端子(106)朝向外壳(102)的电缆端(112)后撤。(An electrical connector (100) includes a housing (102) and a Terminal Position Assurance (TPA) member (104). The housing defines a plurality of cavities (108) extending between the mating and cable ends (114, 112) of the housing (102) and oriented parallel to a cavity axis (120). The housing (102) retains the electrical terminals (106) within the cavities (108) for electrical connection to mating contacts of a mating connector. The TPA member (104) is mounted to a cable end (112) of the housing (102) and is movable relative to the housing (102) between an unlocked position and a locked position. The TPA member (104) is moved from an unlocked position to a locked position along an actuation axis (134) that is perpendicular to the chamber axis (120). The TPA member (104) includes a ledge (224) that projects into the cavity (108) of the housing (102) and into a corresponding withdrawal path (232) of the terminal (106) when the TPA member (104) is in the locked position to prevent withdrawal of the terminal (106) toward the cable end (112) of the housing (102).)

1. An electrical connector (100) comprising:

a housing (102) having a mating end (114) and a cable end (112), the housing (102) defining a plurality of cavities (108) extending between the mating end (114) and the cable end (112) and oriented parallel to a cavity axis (120), the housing (102) retaining electrical terminals (106) within the cavities (108) for electrical connection to mating contacts of a mating connector; and

a Terminal Position Assurance (TPA) member (104) mounted to a cable end (112) of the housing (102) and movable relative to the housing (102) between an unlocked position and a locked position, the TPA member (104) moving from the unlocked position to the locked position along an actuation axis (134) perpendicular to the chamber axis (120), the TPA member (104) including a ledge (224) that protrudes into a chamber (108) of the housing (102) and into a corresponding withdrawal path (232) of the terminal (106) when the TPA member (104) is in the locked position to prevent withdrawal of the terminal (106) toward the cable end (112) of the housing (102).

2. The electrical connector (100) of claim 1, wherein the ledge (224) is spaced from a retreat path (232) of the terminal (106) when the TPA member (104) is in the unlocked position to allow loading and unloading of the terminal (106) relative to the chamber (108).

3. The electrical connector (100) of claim 1, wherein the TPA member (104) comprises a shelf (432) that engages a protrusion of the housing (102) to retain the TPA member (104) on the housing (102), the shelf (432) having a length that is elongated parallel to the actuation axis (134) such that the protrusion slides along the length of the shelf (432) as the TPA member (104) moves relative to the housing (102) between the unlocked and locked positions.

4. The electrical connector (100) of claim 1, wherein one or more of the chambers (108) comprises a mixing chamber section (230) extending from the cable end (112) of the housing (102), the housing (102) defining a first portion of a perimeter of the mixing chamber section (230) and the TPA member (104) defining a second portion of the perimeter of the mixing chamber section (230), wherein movement of the TPA member (104) between an unlocked position and a locked position changes a cross-sectional area of the mixing chamber section (230).

5. The electrical connector (100) of claim 4, wherein one or more of the cavities (108) comprise an integral (single) cavity section (228) extending from the mixing cavity section (230) toward the mating end (114) of the housing (102), the housing (102) defining an entire perimeter of the integral cavity section (228), wherein the ledge (224) of the TPA member (104) is disposed at an interface between the integral cavity section (228) and the mixing cavity section (230).

6. The electrical connector (100) of claim 1, wherein the housing (102) includes a main body (116) extending linearly between the mating end (114) and the cable end (112), the housing (102) including a mounting flange (118) projecting radially from the main body (116), the mounting flange (118) being disposed between and spaced apart from the mating end (114) and the cable end (112), the mounting flange (118) being configured to mount the housing (102) through an opening in a panel.

7. The electrical connector (100) of claim 6, wherein the mounting flange (118) includes a first side (126) facing the cable end (112) of the housing (102) and a second side (128) facing the mating end (114), wherein the electrical connector (100) includes a compression seal (136) mounted to the first side (126) of the mounting flange (118) and extending circumferentially around the body (116) of the housing (102) and the TPA member (104).

8. The electrical connector (100) of claim 1, wherein the TPA member (104) comprises a deflectable latch arm (412) extending parallel to the actuation axis (134) from a fixed end (414) to a distal catch end (416), the housing (102) comprising a locking rib (336), the distal catch end (416) of the latch arm (412) engaging a catch surface (340) of the locking rib (336) when the TPA member (104) is in the locked position to fix the TPA member (104) in the locked position, wherein the distal catch end (416) is spaced apart from the catch surface (340) when the TPA member (104) is in the unlocked position.

9. The electrical connector (100) of claim 1, wherein the housing (102) includes a base surface (302) and first and second lands (304, 306) extending from the base surface (302) to a cable end (112) of the housing (102), the first and second lands (304, 306) defining portions of the chamber (108), the first land (304) being spaced apart from the second land (306) by a channel (308), the TPA member (104) extending through the channel (308) and circumferentially surrounding the first land (304), wherein the TPA member (104) moves toward the second land (306) when the TPA member (104) moves from the unlocked position to the locked position.

10. The electrical connector (100) of claim 9, wherein the first platform (304) comprises a protrusion that engages a shelf (432) of the TPA member (104) to retain the TPA member (104) on the housing (102) in both the locked and unlocked positions, the second platform (306) comprising a locking rib (336) that is engaged by a deflectable latch arm (412) of the TPA member (104) to retain the TPA member (104) in the locked position when the TPA member (104) is in the locked position.

Technical Field

The subject matter herein relates generally to electrical connectors having terminal position assurance devices or members to ensure that electrical terminals are properly loaded and secured within a connector housing.

Background

Electrical connectors typically include electrical terminals held within an insulative housing. The electrical terminals must be properly positioned or placed within the housing in order to successfully mate to corresponding electrical contacts of the mating connector. If one or more of the terminals are not properly positioned, they may not operate as intended when the connector is mated with a mating connector. It may also be difficult to determine which terminal has a fault due to the number of terminals in the housing and poor accessibility of the terminals within the housing.

Another problem with electrical connectors is retention of the terminals. For example, some terminals are retained within the cavity of the housing via a small retention feature (e.g., a latch that extends between the terminal and the housing within the cavity). However, the retention feature may not be robust enough to withstand the pulling force exerted on the cable attached to the terminal, causing the retention feature to fail and causing the terminal to be pulled out of position.

For these reasons, some electrical connectors include Terminal Position Assurance (TPA) devices that are configured to ensure that the terminals are properly loaded within the housing and can support retention of the terminals within the housing. However, the known TPAs have several disadvantages. For example, some TPA devices are loaded inline and axially with the terminals, extending into the chamber through the mating or cable end. However, these end-loaded TPA devices may not be robust enough to withstand axial pushing and/or pulling forces exerted on the terminals. Another type of TPA device is laterally actuated such that the TPA device is moved into the cavity perpendicular to the axis of the terminal to provide a hard stop surface, preventing axial movement of the terminal. Laterally actuated TPA devices may be more robust than in-line TPA devices, but may not be usable due to interference with other features of the connector (e.g., mounting flanges, seals, mating latches or other fasteners, etc.). For example, if the housing is surrounded by a gasket or other compressible seal, the lateral actuation motion of the TPA device can interfere with the gasket.

The problem to be solved is to provide an electrical connector with a TPA device that ensures that the terminals are properly positioned in the housing, provides robust retention support for the terminals, and does not interfere with other features of the connector.

Disclosure of Invention

The problem is solved by an electrical connector comprising a housing and a Terminal Position Assurance (TPA) member. The housing has a mating end and a cable end. The housing defines a plurality of cavities extending between the mating end and the cable end and oriented parallel to the cavity axis. The housing retains the electrical terminals within the cavity for electrical connection to mating contacts of a mating connector. The TPA member is mounted to a cable end of the housing and is movable relative to the housing between an unlocked position and a locked position. The TPA member is moved from an unlocked position to a locked position along an actuation axis that is perpendicular to the chamber axis. The TPA member includes a ledge that projects into the cavity of the housing and into a corresponding withdrawal path of the terminal when the TPA member is in the locked position to prevent withdrawal of the terminal toward the cable end of the housing.

Drawings

The invention will now be described, by way of example, with reference to the accompanying drawings, in which:

fig. 1 is a perspective view of an electrical connector according to an embodiment.

Fig. 2 is an exploded perspective view of an electrical connector according to an embodiment.

Fig. 3A is a perspective view of a portion of an electrical connector showing a housing of the electrical connector and some of the power terminals in cross-section, according to an embodiment.

Fig. 3B is an enlarged view of a subsection of the electrical connector shown in fig. 3A.

Fig. 4A is a perspective view of a portion of a housing at a cable end thereof according to an embodiment.

Fig. 4B is an enlarged view of a sub-portion of the housing shown in fig. 4A.

Fig. 5 is a perspective view of a TPA member of an electrical connector according to an embodiment.

Fig. 6 is a cross-sectional view of a TPA member according to the embodiment shown in fig. 5.

Fig. 7 is a perspective view of a TPA member according to an embodiment ready to be mounted to a housing.

Fig. 8 is a perspective view of an electrical connector according to an embodiment showing a TPA member mounted to a housing in an unlocked position.

Fig. 9 is a close-up perspective view of an electrical connector showing a TPA member mounted to a housing in a locked position, according to an embodiment.

Fig. 10 is a cross-sectional plan view of an electrical connector according to an embodiment showing a TPA member in an unlocked position on a housing.

Fig. 11 is a cross-sectional plan view of an electrical connector according to an embodiment showing the TPA member in a locked position on the housing.

Fig. 12 is a side cross-sectional view of an electrical connector according to an embodiment.

Detailed Description

Fig. 1 is a perspective view of an electrical connector 100 according to an embodiment. Fig. 2 is an exploded perspective view of the electrical connector 100 according to an embodiment. The electrical connector 100 includes a housing 102, a Terminal Position Assurance (TPA) member 104, and a plurality of terminals 106 (shown in fig. 2). The terminals 106 are held within corresponding cavities 108 of the housing 102. The terminals 106 may be electrically connected and mechanically secured to respective cables 110 that project from the housing 102 at a cable end 112 of the housing 102. Only a short section of the cable 110 is shown in fig. 1 and 2, however, the cable 110 may extend to a connection device, such as a battery, computer, etc.

In the illustrated embodiment, the housing 102 has a cable end 112 and a mating end 114. The mating end 114 defines a mating interface for engaging a mating connector (not shown) during a mating operation. Although not shown, the mating end 114 of the housing 102 may define a receptacle that receives a portion of a mating connector therein during a mating operation. The cavity 108 may be open at the cable end 112 and extend toward the mating end 114. For example, the terminals 106 may be loaded into the cavity 108 through the cable end 112. The cavity 108 is fluidly connected (e.g., open) to the mating end 114, either directly or via a socket. Each terminal 106 is loaded into a different chamber 108. The terminals 106 within the housing 102 are configured to electrically connect to corresponding mating contacts of a mating connector. In an embodiment, the chambers 108 are oriented parallel to each other and to the chamber axis 120.

In fig. 1, the electrical connector 100 is an in-line or straight-line connector such that the housing 102 extends linearly from the cable end 112 to the mating end 114. The housing 102 may be elongated parallel to the chamber axis 120. In an alternative embodiment, the electrical connector 100 may not be an in-line connector, such as a right angle connector, where the mating end 114 is oriented transverse to the cable end 112.

The electrical connector 100 may alternatively be a receptacle plug connector that is mounted directly to a device, such as a chassis of a vehicle, a battery compartment, etc., and is configured to mate with a plug connector. For example, in the illustrated embodiment, the housing 102 includes a main body (portion) 116 and a mounting flange 118 connected to the main body 116. The mounting flange 118 is configured to be mechanically fastened to a wall or panel (not shown) to mount the connector 100 through an opening in the panel. In the illustrated embodiment, the main body 116 defines both the cable end 112 and the mating end 114. The chamber 108 extends within the body 116. A mounting flange 118 is located between the cable end 112 and the mating end 114 and is spaced from the ends 112, 114. A mounting flange 118 projects radially outwardly from the body 116.

The mounting flange 118 has a first side 126 facing the cable end 112 and an opposite second side 128 facing the mating end 114. The mounting flange 118 optionally defines openings 122 therethrough for receiving fasteners (not shown), such as bolts and/or screws. The opening 122 may also hold a compression limiter 124 or other support extending between the fastener and the flange 118 to protect the material of the flange 118.

Optionally, the mounting flange 118 may be configured as a sealing panel or wall. The mounting flange 118 may include a compression seal 136 mounted to the first side 126 of the flange 118. The compression seal 136 may comprise a rubber or rubber-like material that is compressed when sandwiched between the first side 126 of the flange 118 and the panel to prevent debris and contaminants from passing through the interface between the panel and the connector 100. In the illustrated embodiment, the compression seal 136 is a hollow band that extends circumferentially around the body 116 of the housing 102 and the TPA member 104, as shown in fig. 1. The compression seal 136 may be a gasket, O-ring, or the like.

As shown in fig. 1, the TPA member 104 is mounted to the housing 102 at or near the cable end 112. As described in more detail herein, the TPA member 104 is movable relative to the housing 102 between an unlocked position and a locked position. For example, the TPA member 104 can be disposed in an unlocked position during assembly. After loading the terminals 106 within the cavities 108, an operator may actuate the TPA member 104 to the locked position. In the locked position, the TPA member 104 is configured to protrude into the cavities 108 to support retention of the terminals 106 in the housing 102. For example, the TPA member 104 includes a feature that locks the terminals 106 in a fixed position relative to the housing 102 by preventing the terminals 106 from backing out through the cable end 112 of the housing 102. The TPA member 104 can provide a secondary means of retaining the terminals 106 in the housing 102, or alternatively, can provide a primary and/or sole means of retaining the terminals 106 in the housing 102.

The TPA member 104 also provides terminal position assurance to indicate whether any of the terminals 106 are improperly positioned within the housing 102. For example, if one or more terminals 106 are not fully loaded within the corresponding chamber 108, the TPA member 104 is prevented from moving to the locked position, which provides a tactile and visual indication to the operator. The TPA member 104 can comprise an electrically insulative (e.g., dielectric) material, such as one or more plastics. Alternatively, the TPA member 104 can comprise one or more metals. The TPA member 104 can be formed by a molding process.

In one or more embodiments described herein, the TPA member 104 is configured to be loaded onto the cable end 112 of the housing 102 in a loading direction 130 parallel to the chamber axis 120. The TPA member 104 is configured to be loaded to an unlocked position. In addition, the TPA member 104 is configured to actuate between an unlocked position and a locked position along an actuation axis 134 (shown in fig. 1) that is perpendicular to the loading direction 130 and the chamber axis 120. Thus, the TPA member 104 is loaded onto the housing 102 parallel to the chamber axis 120, moving perpendicular to the chamber axis 120 between the unlocked and locked positions.

Referring to fig. 2, the terminals 106 of the electrical connector 100 each have a crimp barrel 138 and a mating contact 140. The crimp barrels 138 are crimped to the respective cables 110. The mating contacts 140 define distal ends 142 of the terminals 106 that are closest to the mating end 114 of the housing 102 when loaded into the chamber 108. In the illustrated embodiment, the electrical connector 100 includes power terminals 106a and signal terminals 106 b. The mating contacts 140 of the power terminals 106a are blade contacts and the mating contacts 140 of the signal terminals 106b are pin contacts. In alternative embodiments, the electrical connector 100 may include only one type of terminal, such as only the signal terminals 106b or only the power terminals 106a, and/or the terminals 106 may have different types of mating contacts 140, such as receptacle-type contacts or deflectable beam-type contacts. In the illustrated embodiment, the terminal 106 also includes a shroud 144 mounted to the terminal 106. The shroud 144 is mounted to the mating contact 140 or between the mating contact 140 and the crimp barrel 138. The shroud 144 is spaced from the distal ends 142 of the terminals 106.

The electrical connector 100 may be used in a variety of applications, such as with vehicles, appliances, industrial machinery, and the like. In a non-limiting example, the electrical connector 100 may be installed within an electric vehicle. For example, the electrical connector 100 may represent, or be connected to, a portion of a charger inlet harness of a vehicle for charging a battery of the vehicle.

Fig. 3A is a perspective view of a portion of the electrical connector 100 showing the housing 102 and some of the power terminals 106a in cross-section, according to an embodiment. Fig. 3B is an enlarged view of a subsection 202 of the electrical connector 100 shown in fig. 3A. In fig. 3A and 3B, the TPA member 104 is in a locked position relative to the housing 102. In the illustrated embodiment, the cross-sectional lines do not extend through the TPA member 104.

In an embodiment, the terminals 106 are held in two rows 204, 206 in the connector 100. Cross-hatching extends through the terminals 106 and cables 110 in the first row 204 and the cavities 108 of the housing 102 that receive the terminals 106 of the first row 204. The terminal 106 is positioned in the cavity 108 such that the crimp barrel 138 and the intermediate section 208 of the terminal 106 are generally aligned with the TPA member 104, and the mating contact 140 and the shroud 144 are disposed beyond the TPA member 104 within the cavity 108. Optionally, the shroud 144 may be aligned with the mounting flange 118 of the housing 102. The housing 102 may include one or more protrusions 210 that extend from an inner wall 212 of the housing 102 into the chamber 108. The projections 210 engage the shroud 144 or other portion of the terminal 106 to prevent further movement of the terminal 106 in the loading direction 130. For example, each terminal 106 may reach a fully loaded or fully placed position within the housing 102 when an appropriate component of the terminal 106 (e.g., the jacket 144) abuts against one or more protrusions 210 in the corresponding cavity 108.

In an embodiment, the TPA member 104 includes first chamber walls 214 and second chamber walls 216. Chamber walls 214, 216 extend generally parallel to each other and are connected to each other by first and second end walls 218, 220 at the ends of TPA member 104 and a bridge wall 222 disposed between end walls 218, 220. The end walls 218, 220 may be mirror images of each other. As shown in fig. 3A, the first chamber walls 214 of the TPA member 104 define portions of the chambers 108 of the first row 204 of retention terminals 106. For example, a first chamber wall 214 defines a first portion of a perimeter of each chamber 108 in the first row 204, and although not shown in fig. 3A due to the cross-section, the housing 102 defines a second portion of the perimeter.

First chamber wall 214 includes a ledge 224 that protrudes from first chamber wall 214. When the TPA member 104 is in the locked position, the ledge 224 protrudes beyond the inner wall 212 of the housing 102 into the chamber 108. Referring to fig. 3B, the TPA member 104 may include two ledges 224 extending into each chamber 108. The housing 102 may include a shoulder 226 within each chamber 108 at an interface between a narrow section 228 of the chamber 108 and a wide section 230 of the chamber 108. The narrow section 228 is defined entirely by the housing 102 and may be referred to herein as an integral chamber section 228. The wide section 230 is defined by both the first chamber wall 214 of the TPA member 104 and the housing 102, and may be referred to herein as the mixing chamber section 230.

In an embodiment, the first chamber wall 214 is disposed on the shoulder 226. The ledge 224 protrudes from the shoulder 226 into the chamber 108 (when the TPA member 104 is in the locked position). The ledge 224 extends into the withdrawal path 232 of the terminal 106 to prevent the terminal 106 from being pulled or pushed out of position toward the cable end 112. The pullback path 232 represents the space or cross-sectional area occupied by the terminal 106. For example, the ledge 224 may extend into the space behind the shroud 144 such that the rear end 234 of the shroud 144 is configured to abut the end surface 236 of the ledge 224 to prevent movement of the terminal 106 toward the cable end 112. In an embodiment, when the TPA member 104 is in the unlocked position (as shown in fig. 10), the ledge 224 may not extend into the withdrawal path 232 of the terminal 106, which allows loading and unloading of the terminal 106 relative to the housing 102.

In the illustrated embodiment, the TPA member 104 provides additional retention of the terminals 106 within the cavities 108. For example, as shown in fig. 3B, the shroud 144 includes deflectable fingers 240 that engage a lip 242 of the housing 102 to provide primary retention of the terminals 106 within the cavities 108. Deflectable fingers 240 may not be able to withstand forces exerted on terminals 106 or cables 110 attached to terminals 106 due to size limitations or improper use of fingers 240. Thus, the TPA member 104 can provide additional support for the deflectable fingers 140 to hold the terminals 106 in the correct position.

Fig. 4A is a perspective view of a portion of the cable end 112 of the housing 102, according to an embodiment. The housing 102 includes a base surface 302 and first and second platforms 304, 306 extending from the base surface 302 to the cable end 112. The first platform 304 and the second platform 306 may define or represent the cable end 112 of the housing 102. The base surface 302 may optionally be aligned with the mounting flange 118. For example, the base surface 302 may be coplanar with the first side 126 of the mounting flange 118, and the first and second platforms 304, 306 represent portions of the housing 102 between the mounting flange 118 and the cable end 112.

The first and second lands 304, 306 are contoured protrusions. The contour of the platforms 304, 306 are configured to complement the contour of the TPA member 104 (shown in fig. 3A). For example, the first platform 304 may include two gaps 314 that segment or divide the first platform 304. The gaps 314 are each configured to receive a corresponding one of the bridging walls 222 of the TPA member 104 (as shown in fig. 3A) when the TPA member 104 is mounted on the housing 102. The second platform 306 may have a unitary construction that is not segmented. The second platform 306 may include a planar outer surface 316 along the second platform 306. The outer surface 316 faces away from the first platform 304.

In an embodiment, the first platform 304 is spaced apart from the second platform 306 by a groove 308. In the illustrated embodiment, the groove 308 extends along the entire depth of the platforms 304, 306 from the cable end 112 to the base surface 302, but may extend only a portion of the depth in alternative embodiments. The channel 308 is elongated along the length of the housing 102, and the first and second lands 304, 306 extend parallel to each other along the length of the channel 308. For example, the lands 304, 306 are elongated on either side of the trench 308 between a first end 330 of the lands 304, 306 and an opposing second end 332 of the lands 304, 306.

Optionally, the mounting flange 118 may define a recess or groove 318 along the first side 126 that is configured to receive the compression seal 136 (shown in fig. 1) therein. The groove 318 extends circumferentially around both the first and second lands 304, 306. The compression seal 136 may be secured within the groove 318 via an adhesive or an interference fit with the edges of the groove 318.

Fig. 4B is an enlarged view of the subsection 320 of the housing 102 shown in fig. 4A. At least one of the platforms 304, 306 includes features that connect and retain the TPA member 104 (shown in fig. 3A) to the housing 102. In an embodiment, this feature is provided at the first end 330 and the second end 332 of the platforms 304, 306, although only the first end 330 is visible in fig. 4B. This feature may include a mounting boss 334 and a locking rib 336. Both the mounting tabs 334 and the locking ribs 336 project radially outward from the first ends 330 of the platforms 304, 306. In the illustrated embodiment, the first platform 304 includes a tab 334 and the second platform 306 includes a locking rib 336. As described in more detail herein, the mounting projections 334 are configured to support alignment of the TPA member 104 relative to the housing 102 when the TPA member 104 is mounted to the housing 102. The mounting projections 334 may also support retention of the TPA member 104 on the housing 102 such that the TPA member 104 does not slip off of the platforms 304, 306 at the cable end 112 of the housing 102. The locking ribs 336 may be configured to support securing the TPA member 104 in the locked position, and optionally may be used to prevent the TPA member 104 from being inadvertently moved prematurely from the unlocked position to the locked position (e.g., prior to loading the terminals 106 into the housing 102 as shown in fig. 2). The locking rib 336 on the second platform 306 includes a catch surface 340 facing away from the first platform 304.

In the illustrated embodiment, the locking ribs 336 are disposed between the base surface 302 and the mounting bosses 334, which are disposed along the height of the platforms 304, 306 as measured from the base surface 302 to the cable end 112. In one or more alternative embodiments, the mounting tab 334 and the locking rib 336 may be disposed at similar or overlapping locations along the height of the platforms 304, 306, or the mounting tab 334 may be disposed between the base surface 302 and the locking rib 336 along the height.

Although not shown in fig. 4A or 4B, the platforms 304, 306 may include another mounting tab 334 and another locking rib 336 at the second end 332 of the platforms 304, 306 that mirror the mounting tab 334 and the locking rib 336 at the first end 330.

Fig. 5 is a perspective view of the TPA member 104 of the electrical connector 100 (shown in fig. 1) according to an embodiment. TPA member 104 includes a plurality of walls, including a first chamber wall 214, a second chamber wall 216, a first end wall 218 and a second end wall 220, and two bridge walls 222. Bridging walls 222 are located between end walls 218, 220, and each bridging wall 222 connects to both chamber walls 214, 216. For example, the bridge wall 222 extends parallel to the end walls 218, 220. In an embodiment, the TPA member 104 is hollow, defining a void 402 between the walls 214, 216, 218, 220, 222. In the illustrated embodiment, the TPA member 104 includes two bridge walls 222a, 222b, such that the TPA member 104 defines three voids 402 (e.g., one between the two bridge walls 222a, 222b, one on either side of the bridge walls 222a, 222 b). In other embodiments, the TPA member 104 can have no bridging wall 222, one bridging wall 222, or more than two bridging walls 222.

The TPA member 104 includes a top end 404 and a bottom end 406 opposite the top end 404. As used herein, relative or spatial terms such as "top," "bottom," "upper," "lower," "front," and "rear" are used merely to distinguish elements referenced in the illustrated orientation and do not necessarily require a particular position or orientation in the ambient environment of the TPA member 104 or the electrical connector 100. When the TPA member 104 is mounted to the housing 102, the tip 404 can be proximate to and optionally aligned with the cable end 112 of the housing 102 (as shown in fig. 3A). The bottom end 406 may face toward the mating end 114 (fig. 1) of the connector 100. In an embodiment, the TPA member 104 is open along a top end 404 and a bottom end 406 such that the void 402 extends through the height of the TPA member 104. In the illustrated embodiment, the ledge 224 of the first chamber wall 214 is disposed at the bottom end 406, but may be spaced from the bottom end 406 in other embodiments. Ledge 224 is disposed along an outer surface 418 of first chamber wall 214 that faces away from gap 402 and second chamber wall 216.

The TPA member 104 is oriented with respect to a vertical or height axis 191, a lateral axis 192, and a longitudinal or depth axis 193. The axes 191-193 are perpendicular to each other. While the vertical axis 191 appears to extend generally parallel to gravity, it is understood that the axis 191-193 need not have any particular orientation relative to gravity.

In an embodiment, the TPA member 104 includes at least one alignment post 410 that protrudes beyond the bottom end 406 along the vertical axis 191. In the illustrated embodiment, the TPA member 104 includes two alignment posts 410, but in other embodiments there may be more or less than two alignment posts. When the TPA member 104 is angularly positioned to be mounted to the housing 102 (fig. 1), the vertical axis 191 of the TPA member 104 is aligned with the chamber axis 120 (fig. 1) such that the alignment post 410 extends parallel to the chamber axis 120.

The TPA member 104 also includes at least one deflectable latch arm 412 configured to engage one of the locking ribs 336 (fig. 4B) of the housing 102 to secure the TPA member 104 in the locked position. In the illustrated embodiment, the TPA member 104 includes two latch arms 412, one latch arm 412 located at the first end wall 218 and the other latch arm located at the second end wall 220. The latch arms 412 each overhang between a respective fixed end 414 and a distal hook end 416, the distal hook end 416 being movable relative to the TPA member 104. In the illustrated embodiment, two latch arms 412 extend along the longitudinal axis 193 from a fixed end 414 to a distal hook end 416. When the TPA member 104 is mounted to the housing 102, the latch arms 412 extend parallel to the actuation axis 134 (shown in fig. 1). The latch arms 412 extend from a fixed end 414 to a distal hook end 416 in a direction toward the first chamber wall 214 of the TPA member 104. For example, fixed end 414 is located between second chamber wall 216 and distal hook end 416 along longitudinal axis 193. Distal hook end 416 may be aligned with first chamber wall 214 or may be located adjacent first chamber wall 214.

Fig. 6 is a cross-sectional view of the TPA member 104 according to the embodiment shown in fig. 5. The cross-sectional lines extend parallel to the transverse axis 192 shown in fig. 5, with the first chamber wall 214 cut away to show the void 402 and the interior of the second chamber wall 216. As shown in fig. 6, second chamber wall 216 includes a ledge 424 that is sized and shaped similar to ledge 224 of first chamber wall 214 (shown in fig. 5). Ledge 424 is disposed along an inner surface 426 of second chamber wall 216, inner surface 426 facing first chamber wall 214 and defining a portion of void 402. The ledge 424 protrudes from the inner surface 426 into the void 402. Ledge 424 of second chamber wall 216 protrudes in the same direction as ledge 224 of first chamber wall 214. For example, the ledge 224 protrudes away from the void 402, as shown in FIG. 5.

In an embodiment, the first end wall 218 of the TPA member 104 defines a recess 428 along an inner surface 430 thereof facing the void 402. The bottom end of the recess 428 is defined by a shelf 432 of the first end wall 218. Shelf 432 has a length that is elongated along longitudinal axis 193 (fig. 5). When the TPA member 104 is mounted to the housing 102 (as shown in fig. 4A), the mounting projections 334 (fig. 4B) along the first end 330 of the platforms 304, 306 are received within the recesses 428 of the first end wall 218. The recess 428 is wider than the mounting protrusion 334 along the longitudinal axis 193, thus allowing relative movement between the TPA member 104 and the housing 102 when the TPA member 104 is held on the housing 102. For example, the mounting protrusion 334 within the recess 428 may slide along the shelf 432 as the TPA member 104 moves relative to the housing 102 along the actuation axis 134 (fig. 1).

The first end wall 218 may define a guide slot 434 along the inner surface 430. The guide slot 434 is elongated along a vertical axis 191 (fig. 5) and extends from the bottom end 406 of the TPA member 104. The guide slot 434 is aligned with the recess 428 such that the guide slot 434 is disposed vertically below the recess 428 (e.g., between the recess 428 and the bottom end 406). The upper end of the guide slot 434 is spaced from the recess 428 by a ridge 436 of the first end wall 218. The shelf 432 of the recess 428 is a top surface of the ridge 436. In an embodiment, the guide slot 434 receives the mounting protrusion 334 of the housing 102 therein (as shown in fig. 4B) during mounting of the TPA member 104 to the housing 102. For example, when the TPA member 104 is loaded onto the first platform 304 (fig. 4B) of the housing 102, the mounting tabs 334 are received within the guide slots 434 at the bottom ends 406 and slide upward within the guide slots 434. Finally, the mounting boss 334 abuts the ridge 436 at the upper end of the guide slot 434. The ridge 436 resists, but does not prevent, further movement of the TPA member 104 in the loading direction 130 (fig. 2) because the ridge 43 deflects around the mounting projection 334 of the housing 102 due to sufficient force exerted on the TPA member 104 in the loading direction 130. When the shelf 432 of the ridge 436 passes over the mounting tab 334, the mounting tab 334 enters the recess 428.

In an embodiment, the guide slot 434 is narrower than the recess 428 along the longitudinal axis 193, and the guide slot 434 is not centered with respect to the recess 428. Guide slot 434 is aligned with a portion of recess 428 that is positioned closer to first chamber wall 214 (fig. 5) relative to second chamber wall 216. The shape and location of the guide slot 434 may be configured to ensure that the TPA member 104 reaches the unlocked position when mounted to the housing 102, preventing the TPA member 104 from being loaded directly into the locked position.

Although not shown in fig. 6, in an embodiment, the second end wall 220 of the TPA member 104 is a mirror image of the first end wall 218. For example, the inner surface 438 of the second endwall 220 (which faces the void 402) may also include a recess, a ridge with a shelf, and a guide slot, which are the same as or at least similar to the recess 428, ridge 436, and guide slot 434 of the first endwall 218.

Fig. 7-9 illustrate an assembly process of the electrical connector 100 according to an embodiment including mounting and actuating the TPA member 104 relative to the housing 102. For example, fig. 7 is a perspective view of the TPA member 104 in preparation for mounting to the housing 102 according to an embodiment. The TPA member 104 is mounted to the cable end 112 of the housing 102 by moving the TPA member 104 in a loading direction 130 parallel to the chamber axis 120 of the housing 102. The TPA member 104 is oriented such that the bottom end 406 faces the mating end 114 of the housing 102. When the TPA member 104 is loaded onto the housing 102, the alignment posts 410 that protrude beyond the bottom end 406 are received in the channels 308 between the first and second lands 304, 306 of the housing 102. The alignment posts 410 may extend into corresponding guide openings (not shown) between the chambers 108 of the housing 102. The mounting tabs 334 at the first and second ends 330, 332 of the platforms 304, 306 are received in corresponding guide slots 434 (fig. 6) of the first and second end walls 218, 220 of the TPA member 104. When the mounting protrusion 334 enters the recess 428 (fig. 6) of the end walls 218, 220, the TPA member 104 is fully loaded to the housing 102.

Fig. 8 is a perspective view of the electrical connector 100 showing the TPA member 104 mounted to the housing 102 in an unlocked position, according to an embodiment. In the illustrated embodiment, when the TPA member 104 is mounted to the housing 102, the TPA member 104 extends into the channel 308 (shown in fig. 7) and circumferentially surrounds the first platform 304 of the housing 102. For example, the segmented first platform 304 is received within the void 402 of the TPA member 104. The bridging wall 222 of the TPA member 104 is received in the gap 314 of the first platform 304.

In an embodiment, the TPA member 104 and the lands 304, 306 of the housing 102 collectively define the wide or mixing chamber section 230 of the chamber 108. For example, the TPA member 104 defines a portion of the perimeter of each mixing chamber section 230, and a corresponding one of the lands 304, 306 of the housing 102 defines the remainder of the perimeter. In the illustrated embodiment, the connector 100 includes two rows 502, 504 of cavities 108, but may have more or less than two rows in other embodiments. The first platform 304 of the housing 102 defines portions of the chambers 108 in the first row 502, and the second platform 306 defines portions of the chambers 108 in the second row 504.

For example, the mixing chamber sections 230 of the two power chambers 108a in the first row 502 are defined by the first platform 304 of the housing 102 and the second chamber wall 216 of the TPA member 104. The power cavity 108a is configured to receive the power terminal 106a (shown in fig. 2). The first row 502 also includes two signal cavities 108b configured to receive signal terminals 106b (fig. 2). The signal chamber 108b may be smaller than the power chamber 108 a. In the illustrated embodiment, the mixing chamber section 230 of the signal chamber 108b is defined by the first platform 304 and the bridging wall 222 of the TPA member 104. In the illustrated embodiment, the second row 504 of chambers 108 has three power chambers 108a, and the mixing chamber section 230 thereof is defined by the second platform 306 and the first chamber wall 214 of the housing 102.

In the unlocked position of the TPA member 104, the connector 100 is configured to allow the terminals 106 (fig. 2) to be insertable into the cavities 108. As shown in fig. 8, the visible latch arms 412 of the TPA member 104 do not latch to the locking ribs 336 on the second platform 306 of the housing 102. After the terminal 106B is loaded into the chamber 108, the TPA member 104 can be actuated to move from the unlocked position to the locked position. The TPA member 104 moves along the actuation axis 134 in the locking direction 510 from the unlocked position to the locked position. The movement in the locking direction 510 may be perpendicular to the movement along the chamber axis 120 (fig. 7) in the loading direction 130. When the TPA member 104 is moved in the locking direction 510, the TPA member 104 can be moved toward the second platform 306 of the housing 102.

Fig. 9 is a close-up perspective view of the electrical connector 100 showing the TPA member 104 mounted to the housing 102 in a locked position, according to an embodiment. In the illustrated embodiment, the terminals 106 and corresponding cables 110 are located within corresponding cavities 108 of the connector 100. In the latched position, the distal hook end 416 of the latch arm 412 engages and latches to the catch surface 340 of the locking rib 336 on the second platform 306 of the housing 102. The engagement between the latch arm 412 and the locking rib 336 may secure the TPA member 104 in the locked position, preventing reverse movement of the TPA member 104 relative to the housing 102 toward the unlocked position.

Fig. 10 is a cross-sectional plan view of the electrical connector 100 showing the TPA member 104 in an unlocked position on the housing 102, in accordance with an embodiment. The chambers 108 of the two rows 502, 504 are visible in fig. 10, including power chambers 108a and signal chambers 108 b. The first chamber wall 214 of the TPA member 104 is disposed in a channel 308 of the housing 102 between the first and second lands 304, 306.

When the TPA member 104 is in the unlocked position, as shown in fig. 10, the ledges 224, 424 of the TPA member 104 do not extend into the withdrawal path 232 (shown in fig. 3B) of the terminals 106 (fig. 3B). Alternatively, the ledges 224, 424 may be recessed laterally relative to the narrow section 228 of the chamber 108 that is entirely defined by the housing 102 such that the ledges 224, 424 do not protrude into the chamber 108. As the TPA member 104 is mounted to the housing 102, the mounting projections 334 are received within the corresponding recesses 428 of the TPA member 104 and can engage the shelves 432. The latch arms 412 of the TPA member 104 are not connected to the corresponding locking ribs 336. In an embodiment, the distal hook end 416 of the latch arm 412 may be configured to abut against the locking rib 336 to prevent the TPA member 104 from being inadvertently moved to the locked position along the locking direction 510.

Fig. 11 is a cross-sectional plan view of the electrical connector 100 showing the TPA member 104 in a locked position on the housing 102, in accordance with an embodiment. The terminals 106 (shown in fig. 2) are not shown in fig. 11, although the terminals 106 are loaded into the chamber 108 prior to actuation of the TPA member 104. The only change is the position of the TPA member 104 relative to the housing 102 such that the TPA member 104 is displaced toward the second platform 306 of the housing 102, as compared to fig. 10. The mounting protrusion 334 may slide within the recess 428 along the shelf 432 when the TPA member 104 is actuated in the locking direction 510. The distal hook end 416 of the latch arm 412 initially deflects around the locking rib 336 and then latches onto the catch surface 340 to secure the TPA member 104 in the locked position.

As shown in fig. 11, the cross-sectional area of the chamber 108 along the mixing or wide section 230 is changed due to the relative movement of the TPA member 104. Specifically, movement toward the locked position reduces the cross-sectional area of the mixing section 230 of the chamber 108. The ledges 224, 424 of the TPA member 104 extend into the chamber 108, including into the power chamber 108a and the signal chamber 108 b. The ledges 224, 424 extend into the pullback path 232 to prevent pullback of the terminal 106, as described with reference to fig. 3B.

Fig. 12 is a side cross-sectional view of an electrical connector 100 according to an embodiment. The TPA member 104 is shown in an unlocked position on the housing 102. The ledges 224, 424 of the TPA member 104 may be disposed on the base surface 302 of the housing 102. In the illustrated embodiment, the base surface 302 is aligned with the mounting flange 118 of the housing 102. For example, the base surface 302 is recessed relative to the first side 126 of the mounting flange 118 and the compression seal 136. By loading the TPA member 104 parallel to the chamber axis 120, the TPA member 104 can reach the base surface 302 without interfering with the compression seal 136 or the mounting flange 118. By configuring the TPA member 104 to actuate in a locking direction 510 perpendicular to the chamber axis 120, the TPA member 104 is able to withstand relatively large pull-out forces exerted on the terminals 106 and associated cables 110.

The illustrated embodiment shows two terminals 106 that are not fully loaded into corresponding cavities 108 of the housing 102. The TPA member 104 cannot be actuated in the locking direction 510 to the locked position because the terminals 106 are not fully loaded. For example, the ledges 224, 424 will abut the terminal 106 (e.g., the shroud 144 of the terminal 106) preventing further movement in the locking direction 510. The TPA member 104 provides terminal position assurance because the obstructed motion indicates to the user that at least one of the terminals 106 is not fully loaded.